Analysis the effect of tool pin profile on elongation, macro-micro structure, thermal and mechanical characteristics of Friction stir welded  2050-T84-Al-Cu-Li alloy plates

Analysis the effect of tool pin profile on elongation, macro-micro structure, thermal and mechanical characteristics of Friction stir welded 2050-T84-Al-Cu-Li alloy plates | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Analysis the effect of tool pin profile on elongation, macro-micro structure, thermal and mechanical characteristics of Friction stir welded 2050-T84-Al-Cu-Li alloy plates Gurusewak Kesharwani, Dr. Sanjeev Kumar, Dr. Tameshwer Nath This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8015507/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study explores the impact of various tool pin profiles—cylindrical, conical, threaded, non-threaded, and a novel hybrid (square + threaded)—on the elongation, macro/microstructure, thermal, and mechanical properties of friction stir welded (FSW) 2050- T84 Al-Cu-Li alloy plates. The results reveal that the tool pin profile significantly affects weld quality, particularly elongation and bead structure. The hybrid pin profile, at 1400 rpm and 4 mm/s, achieved the best performance with a tensile strength of 404.2 MPa, elongation of 7.56%, and joint efficiency of 76.4%. It generated the highest heat input (1180 KJ/m) with optimal flow characteristics and lower axial force. Localized heat at the tip (25 KJ/m) and pin side (330 KJ/m) promoted refined equiaxed grains in the nugget zone and elongated grains in the TMAZ. SEM analysis confirmed ductile fracture surfaces. This work provides valuable guidance for optimizing FSW tool design and process parameters to enhance weld quality. Friction stir welding cylindrical tool pin profile conical tool pin profile hybrid tool pin profile Percentage elongation Heat-Affected -weld zone Tensile- yield strength Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8015507","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":538949165,"identity":"6f01706b-d786-46b6-a894-1dad2a3b6766","order_by":0,"name":"Gurusewak Kesharwani","email":"","orcid":"","institution":"Swami Vivekanand Subharti University","correspondingAuthor":false,"prefix":"","firstName":"Gurusewak","middleName":"","lastName":"Kesharwani","suffix":""},{"id":538949166,"identity":"c3dc5813-9d45-4f25-943a-dac63c59af14","order_by":1,"name":"Dr. Sanjeev Kumar","email":"","orcid":"","institution":"Swami Vivekanand Subharti 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plates","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Friction stir welding, cylindrical tool pin profile, conical tool pin profile, hybrid tool pin profile, Percentage elongation, Heat-Affected -weld zone, Tensile- yield strength","lastPublishedDoi":"10.21203/rs.3.rs-8015507/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8015507/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study explores the impact of various tool pin profiles\u0026mdash;cylindrical, conical, threaded, non-threaded, and a novel hybrid (square\u0026thinsp;+\u0026thinsp;threaded)\u0026mdash;on the elongation, macro/microstructure, thermal, and mechanical properties of friction stir welded (FSW) 2050- T84 Al-Cu-Li alloy plates. The results reveal that the tool pin profile significantly affects weld quality, particularly elongation and bead structure. The hybrid pin profile, at 1400 rpm and 4 mm/s, achieved the best performance with a tensile strength of 404.2 MPa, elongation of 7.56%, and joint efficiency of 76.4%. It generated the highest heat input (1180 KJ/m) with optimal flow characteristics and lower axial force. Localized heat at the tip (25 KJ/m) and pin side (330 KJ/m) promoted refined equiaxed grains in the nugget zone and elongated grains in the TMAZ. SEM analysis confirmed ductile fracture surfaces. This work provides valuable guidance for optimizing FSW tool design and process parameters to enhance weld quality.\u003c/p\u003e","manuscriptTitle":"Analysis the effect of tool pin profile on elongation, macro-micro structure, thermal and mechanical characteristics of Friction stir welded 2050-T84-Al-Cu-Li alloy plates","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-04 09:31:20","doi":"10.21203/rs.3.rs-8015507/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"4f136b0f-bb5d-4014-acf9-f37622fb2f6f","owner":[],"postedDate":"November 4th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-11-13T21:23:20+00:00","versionOfRecord":[],"versionCreatedAt":"2025-11-04 09:31:20","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8015507","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8015507","identity":"rs-8015507","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}